JPS6020180B2 - Decorative board manufacturing method - Google Patents

Description

[Detailed description of the invention] The present invention relates to a method for manufacturing an a-shaped plate by thermoforming.

- The gloss of the decorative board surface is uniform due to the adhesion and thermo-pressure molding.
Although the overall change can be achieved by, for example, applying a drawing process to the mirror plate, changing the gloss according to the pattern of the decorative paper is difficult due to the process of hot press molding. Furthermore, it is difficult to change the thickness of the ink layer in a decorative board formed by thermo-pressure molding. The present inventors have arrived at the present invention as a result of research into various methods of manufacturing decorative boards that simultaneously change the gloss according to the pattern of the Iqsalmon paper and change the thickness of the ink layer using a hot-press molding process. It is.

That is, in the present invention, impregnated decorative paper is layered on the base material with its pattern layer facing up, impregnated overlay paper is layered on top of that as needed, and curable ink containing an extender pigment is further layered on top of that. A laminate formed by stacking tenacious films having a pattern layer with the pattern layer facing down is hot-press molded between a pair of hot platens, and then the pattern layer is removed by peeling off the release film. The gist of the present invention is a method for producing a decorative board, which is characterized by transferring the laminate to the decorative paper side. Hereinafter, the above-described present invention will be explained with reference to the drawings.

First, in the method of the present invention, the laminate A is sandwiched between a pair of hot platens 1 and 1' as shown in the first figure, and then hot-press molded.

In FIG. 1, the laminate A has, from the bottom, a base material 2, an impregnated salmon paper i, an impregnated overlay paper 4 interposed as necessary, and a pattern layer 5 made of a curable ink containing an extender pigment. The film 6 is laminated in order. The impregnated Irihoko paper 3 is entirely impregnated with resin 7, and the pattern layer 9 provided on the decorative base paper 8 is coated with the impregnated overlay paper 4.
placed towards the side. Furthermore, the pattern layer 5 provided on the release film 6 is placed facing the impregnated overlay paper 4 side. The laminate A is preferably placed on a releasable film between a pair of hot platens 1 and 1' with a mirror plate 10 interposed therebetween.
For example, in the case of high pressure melamine, 140 to 150 qo, 7
It is hot-pressed under conditions of 0 to 100 k9/kg and 15 to 20 minutes. Thereafter, the laminate A is taken out from between the hot discs, and as shown in the second figure, the releasable film 6 is peeled off to transfer the pattern layer 5 to the decorative paper side to obtain a decorative board. For the above-mentioned base material, materials such as core paper impregnated with phenolic resin are usually used in the high-pressure melamine method, and plywood and particle board are used in the low-pressure melamine method and DAP (diallyl phthalate resin) molding method. etc. are used.

Further, ordinary paper such as titanium paper is used as the above-mentioned decorative paper, and as the overlay paper, 15 to 30 days per coat is preferably used. These are used by being impregnated with a desired hardening resin such as melamine resin, diallyl phthalate resin, unsaturated polyester resin, etc. by a conventional method. As the above-mentioned template film, films of polypropylene, saturated polyester, nylon, cellulose, etc. can be used, and the gloss is preferably adjusted by sandblasting embossing before use. In addition, in order to provide a pattern layer on the adjoining film, a thermosetting acrylic emulsion, a melamine resin-added acrylic emulsion, or the like is used as a base, and calcium carbonate, precipitated barium sulfate, kaolin, aluminum hydroxide, carbonate, etc. An ink is used in which 30 to 6 t% of magnesium, silica, etc. are mixed, and further gold, silver powder, titanium pigment, etc. are added as necessary to adjust the solid content of the ink to 50 to 9 t% of the ink. It is effective to use pearlescent pigments such as titanium oxide, mica, and aluminum hydroxide as the extender pigments because pearl coloring can be obtained at the same time. The pattern layer is provided by printing methods such as silk screen, gravure, and rotary screen. It is desirable to print the pattern layer thickly in order to improve the abrasion resistance after molding. Therefore, it is preferable that the pattern layer has a thickness of about 20 to 100 mm. Such a thickness is preferable from the viewpoint of physical properties since it competes with the overlay paper of ordinary hot-press molded decorative laminates.
After printing, the pattern layer must have a matte surface and be molded without changing its shape from when it was printed.
As is clear from the above explanation, according to the method of the present invention, a pattern layer containing an extender pigment is formed on the surface of the heat-press-molded IQ disc, so that the gloss state can be partially changed. Furthermore, when a pearl pigment is used as an extender pigment, a pearl color can be obtained.

In the present invention, when an overlay paper is interposed between the pattern layer and the decorative paper, the pearlescent coloring effect can be further enhanced and the depth effect of the pattern can be further imparted. Also,
According to the method of the present invention, since the pattern layer is formed on the surface, it is on a plane different from the pattern of the decorative paper, and since the amount of ink in the pattern layer can be considerably increased, surface effects due to height differences can be avoided. An excellent decorative board can be obtained. Furthermore, if the pattern layer on the decorative paper corresponds to the pattern of the pattern layer, the effect of changing the gloss will be further exhibited. Next, the present invention will be explained in more detail with reference to Examples.

[Example 1] Titanium paper (
1 of cellulose acetate on one side
5 skin%, pigment 7M%, solvent (ethyl acetate; toluene = 1
:1) 6 fine t%, extender pigment (calcium carbonate) 15wt
yellow consisting of % (using cadmium yellow as pigment)
A decorative paper with a pattern layer formed by gravure printing using blue (also cyanine blue) ink is coated with melamine resin (Nippon Carbide Co., Ltd., Nikaresin S-260).
) The impregnated IQ ship paper was layered with the pattern layer facing up.

Next, an impregnated overlay paper obtained by impregnating an overlay paper (Daifuku Paper Co., Ltd., 20/20) with the melamine resin was then layered thereon. Furthermore, on one side of the stretched polypropylene (50r), 24 wt% of the melamine resin,
Water 1 t%, aluminum hydroxide (manufactured by Showa Denko Co., Ltd., /・
Ink (viscosity 5
#40 screen (mesh/i
A laminate was formed by stacking a releasable film having a pattern layer with an ink film of 100 μm (solid content) with the pattern layer facing down, which was obtained by printing with a rotary screen made using a rotary screen. . After that, the above laminate was placed on the releasable film with a mirror plate interposed between a pair of heating plates at 14 to 80k.
9/ When the stretched polypropylene was hot-press molded for 2 minutes and then peeled off, the pattern layer was transferred to the decorative paper side, the gloss changed, and the melamine decorative board had an excellent surface three-dimensional effect. Obtained.

[Example 2] In Example 1, the same results as in Example 1 were obtained even when a key-shaped film was used in which a pattern layer was formed using an ink having the following composition.

[Example 3] On top of the plywood, impregnated salmon paper made by combining the same decorative paper as in Example 1 with DAP resin (manufactured by Sumitomo Chemical Co., Ltd., Dapon) was layered with the pattern layer facing up, and then layered on top of that. Then, the releasable films prepared as follows were stacked with the pattern layer facing down to form a laminate.

Here, the template film is a polyester film (1
Melamine resin (same as Example 1) on one side of 2r)
Sakaki t%, acrylic resin (manufactured by Hitachisei, Hitaloid, resin content 40-5 t%) 1%, aluminum hydroxide (Hygilite) 3%, xylene 2t%, butyl acetate 2t% The resulting ink film was 30~40mm (
A material having a pattern layer of solid content was used. The above laminate is placed on the rock-shaped film with a mirror plate interposed between a pair of heating plates.
14,000, 20 kg/base for 5 minutes, and then, when the polyester film was peeled off, the gloss state had changed, and a DAP decorative board with good appearance and physical properties was obtained. The method of the present invention, which makes it possible to obtain decorative laminates with such excellent performance, can be applied to various hot-press moldings of high-pressure melamine, low-pressure melamine, polyester, diallyl phthalate, and the like.

[Brief explanation of the drawing]

1 and 2 are schematic cross-sectional views for explaining the manufacturing method of the present invention. 1, 1'...Hot plate, 2...Motomura, 3.
... Impregnated decorative paper, 4 ... Impregnated overlay paper, 5 ... Pattern layer made of curable ink containing extender pigment, 6 ... Release film, 7 ... ...Impregnated resin, 8... Decorative base paper, 9... Pattern layer, 1
0... Mirror plate. Figure 1 Figure 2

Claims (1)

[Claims] 1 Lay the impregnated decorative paper on the base material with its pattern layer facing up, and if necessary, layer the impregnated overlay paper on top of it,
Further, a release film having a pattern layer with a thickness of 20 to 100 μm provided by a printing method using a curable ink containing an extender pigment is layered on top of the film, with the pattern layer facing down, and a pair of laminates are heated. 1. A method for producing a decorative board, which comprises performing hot-press molding between discs and then peeling off the release film to transfer the pattern layer to the decorative paper side.